Dual-Face Dual-Split Concrete Product

ABSTRACT

A dual-face dual-split concrete product comprises a first face of horizontal length X and an opposing second face of horizontal length Y, the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X&gt;Y; generally opposing sidewalls that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalls, with the top face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product.

CROSS-REFERENCE(S) TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Patent Application No. 61/613,483, filed Mar. 20, 2012, all of which is hereby incorporated by reference to the extent not inconsistent with the disclosure herewith.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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REFERENCE(S) TO MICROFICHE APPENDIX AND/OR COPYRIGHT PROTECTION

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BACKGROUND

1. Field

In general, the inventive arrangements relate to concrete products, and, more specifically, to a dual-face dual-split concrete block that is particularly useful when constructing and/or arranging landscaping elements.

2. Description of Related Art

For illustrative, exemplary, representative, and non-limiting purposes, preferred embodiments of the inventive arrangements will be described in terms of landscaping elements. However, the inventive arrangements are not limited in this regard.

Now then, concrete products are well-known landscaping elements, and they are often used as a preferred way to construct and/or arrange retaining walls, landscaping wails, etc. As such, they are often assembled in courses, with each course comprising a plurality of such concrete products.

SUMMARY

In one embodiment, a dual-face dual-split concrete product comprises a first face of horizontal length X and an opposing second face of horizontal length Y, the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X>Y; generally opposing sidewalk that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalk, with the to face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

A clear conception of the inventive arrangements, and of various construction and operational aspects of typical mechanisms provided by such arrangements, are readily apparent by referring to the following illustrative, exemplary, representative, and non-limiting figures, which form an integral part of this specification, in which like numerals generally designate the same elements in the several views, and in which:

FIG. 1A is an exaggerated top view of a concrete block according to the inventive arrangements;

FIG. 1B is a front view of the concrete block of FIG. 1;

FIG. 1C is a back view of the concrete block of FIG. 1;

FIG. 2A is a top view of a single ingot formed from a mold for use in accord with the inventive arrangements;

FIG. 2B is the same ingot of FIG. 2A, representatively showing six concrete products of FIG. 1 arranged in a conjugate, alternating arrangement, particularly prior to separation therebetween into individual concrete blocks in accord with the inventive arrangements;

FIG. 3 is a top view of multiple adjacent ingots, such as of FIG. 2;

FIG. 4A is a top view of a top knife for cutting three adjacent ingots in accord with the inventive arrangements;

FIG. 4R is a top view of bottom knife in mating alignment with the top knife of FIG. 4A;

FIG. 5A is a top view of a top knife for cutting n adjacent ingots in accord with the inventive arrangements;

FIG. 5B is a top view of a bottom knife in mating alignment with the top knife of FIG. 5A; and

FIG. 6 is a simplified, composite top view of various knife cuts overlaying three multiple adjacent ingots advancing over time.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to the figures, preferred embodiments of the inventive arrangements will be described in terms of landscaping elements. However, the inventive arrangements are not limited in this regard.

Now then, referring to FIGS. 1A-1C, a three dimensional concrete block 10 has an approximate trapezoidal shape 12 (parallel lines shown in phantom) when viewed from a top view (FIG. 1A). The concrete block 10 has a first face 14 and an opposing second face 16, the first face 14 and second face 16 being generally parallel to one another in orientation according to the trapezoidal shape 12. Preferably, the first face 14 and second face 16 are joined by opposing side walls 18 connecting therebetween. Preferably, a horizontal length of the first face 14 (X) is longer than a horizontal length of the second face 16 (Y) as measured between the sidewalls 18 across the concrete block 10—i.e., X>V. As a result, the opposing sidewalls 18 generally taper in from the first face 14 to the second face 16 when shown in top view (FIG. 1A) due to the first face 14 being longer in horizontal length than the second face 16 (i.e., X>Y) as measured across the concrete block 10. A generally perpendicular distance between the first face 14 and second face 16 defines a general depth D of the concrete block 10.

The first face 14 and second face 16, as well as the sidewalls 18, are further joined by a top face 20 and generally opposing bottom face 22, with a generally perpendicular distance between the top face 20 and bottom face 22 defining a general height H of the concrete block 10.

Distinctions between the first face 14 and the second face 16, as well as between the top face 20 and the bottom face 22, are arbitrary reference indicators for simplicity only; they may be altered and/or interchanged therebetween as desired.

In addition, the concrete block 10 is suitably dimensioned according to preferred dimensions, depending, far example, on one or more desired applications for the concrete block 10, suitably chosen by those skilled in these arts.

Now then, referring to FIGS. 2A-2B, a single ingot 24 is farmed from a concrete mold (mold not shown) for use in accord with the inventive arrangements. More specifically, one or more of the concrete blocks 10 of FIG. 1 (such as, preferably, six concrete blocks 10 a-10 f) are shape-molded in a conjugate, alternating arrangement within the ingot 24, with generally adjacent first faces 14 a-14 f and generally adjacent second faces 16 a-16 f to be formed between alternating concrete blocks 10 a-10 f according to the inventive arrangements (with exceptions, for example, at the ends 26 a, 26 f of the ingot 24 for a non-adjacent first face 14 a of an ending concrete block 10 a and a corresponding non-adjacent first face 14 f of another ending concrete block 10 f). The ends 26 a, 26 f of the ingot 24 are waste pieces, not generally forming a part of the concrete blocks 10 a, 10 f. Preferably, waste components are minimized. In any event, the concrete blocks 10 a-10 f of the single ingot 24 are shown prior to physical separation therebetween, and the ingot 24 is preferably of any suitable length, likely largely dependent on a chosen mold (mold not shown) suitably chosen by those skilled in these arts.

Referring now to FIG. 3, multiple ingots 24 of FIG. 2 are adjacent to one another, such as two adjacent ingots 24 a-24 b, three adjacent ingots 24 a-24 c, and/or more adjacent ingots 24 a-24 n (with an n^(th) ingot representatively comprising n adjacent ingots 24). Preferably, adjacent ingots 24 a-24 n are molded simultaneously with one another, such as by mold forming techniques known in these arts. Preferably, the ingots 24 a-24 n are suitably spaced apart from one another by a suitable mold distance M, but they are also preferably brought into physical contact with one another (i.e., M=0) by known clamping techniques at the outer peripheries of the multiple ingots 24 a-24 n when cutting the concrete blocks 10 a-10 f according to the inventive arrangements.

Preferably, the individual concrete blocks 10 a-10 f are cut and separated from one another along both the first faces 14 a-14 f and the second faces 16 a-16 f. Accordingly, each concrete block 10 a-10 f is dual-faced: both the first face 14 and the second face 16 of the concrete block 10 comprise outwardly facing faces of same, split according to the inventive arrangements and later preferably arranged as desired (e.g., into retaining walls, landscaping walls, etc.).

Likewise, each concrete block 10 a-10 f is also dual-split: they are cut and separated along both their first faces 14 and their second faces 16 of the concrete block 10, again split according to the inventive arrangements and later preferably arranged as desired (e.g., into retaining walls, landscaping walls, etc.).

Now then, referring to FIGS. 4-5, a cutting assembly 28 is used to cut the bigots 24 a-24 n of FIGS. 2-3 along the first faces 14 a-14 f and the second faces 16 a-16 f of the concrete blocks 10 a-10 f. More specifically, the cutting assembly 28 cuts the ingots 24 a-24 n to define the first faces 14 a-14 f and the second faces 16 a-16 f of the concrete blocks 10 a-10 f, thereby forming the dual-face dual-split concrete blocks 10 of FIGS. 1A-1C.

By the inventive arrangements, the same cutting assembly 28 cuts both the first faces 14 a-14 f and the second faces 16 a-16 f within the ingots 24 a-24 n. In other words, the single cutting assembly 28 is used to cut along both the first faces 14 a-14 f and the second faces 16 a-16 f of the ingots 24 a-24 n. Even more specifically, the cutting assembly 28 is contoured to cut according; to both the first faces 14 a-14 f of the concrete blocks 10 a-10 f as well as the second faces 16 a-16 f of the concrete blocks 10 a-10 f.

Accordingly, a single cutting assembly 28 can be used to cut both the first faces 14 a-14 f and the second faces 16 a-16 f of the ingots 24 a-24 n into the concrete blocks 10 a-10 f of the inventive arrangements. Preferably, the cutting assembly 28 comprises a top knife 30 a and a bottom knife 30 b in mating alignment therewith. The two knifes 30 are brought into close physical proximity with one another under suitable force to sever one ingot 24 or multiple adjacent ingots 24 a-24 n according to the described contours of the cutting surfaces 32 of the knives 30. In one preferred embodiment (e.g., FIG. 4), a single cut by the cutting assembly 28 cuts three adjacent ingots 24 a-24 c. In another preferred embodiment (e.g., FIG. 5), a single cut by the cutting assembly 28 cuts a adjacent ingots 24 a-24 n.

The dual-face dual-split concrete block 10 is thereby cut by the single cutting assembly 28 of FIGS. 4-5. More specifically, as the one or more ingots 24 a-24 n advance along a conveyor or the like (not shown), the cutting assembly 28 cuts the concrete blocks 10 a-10 f along each of the first faces 14 a-14 f and each of the second faces 16 a-16 f of respective concrete blocks 10 a-10 f. Because of the conjugate, alternate arrangement of the ingots 24 a-24 n, each cut has a desired, and alternating, effect on particular concrete blocks 10. Accordingly, the knifes 30 cut, at different times, the different faces 14, 16 of the different ingots 24 a-24 n, particularly depending on a particular ingot 24 arrangement, including multiple adjacent ingots 24 a-24 n. For example, depending on a particular cut, a knife 30 cuts a first face 14 a of a concrete block 10 a at a first time t₁ along a single ingot 24 a, then cuts a second face 16 a of the same concrete block 10 a at a second time t₂ along the same single ingot 24 a. This second cut at time t₂ also forms the second face 16 b of the next concrete block 10 h along that same ingot 24 a. Likewise, a third cut at time t₃ forms the first face 14 b of the next concrete block 10 h, and simultaneously the first face 14 c of the next concrete block 10 c along the same ingot 24 a. This pattern continues for cutting the length of the single ingot 24 a over an appropriate number of time intervals and cuts.

At the same time, because the knifes 30 also span multiple ingots 24 a-24 n, the first cut at time t₂ also cuts the second face 16 of an adjacent ingot 241, as well as a first face 14 of another adjacent ingot 24 c. This pattern also continues for cutting any number of adjacent bigots 24 a-24 n.

As described, the knives 30 make the same cuts at each time interval. However, because of the alternating arrangements of the concrete blocks 10 to be formed—both along a single ingot 24, as well as across multiple ingots 24 a-24 n different, and alternating, first faces 14 and second faces 16 of the various concrete blocks 10 are formed, oftentimes simultaneously. Sometimes the knives 30 will contact an ingot 24 and form (i) a first face 14 only (ii) a second face 16 only; (iii) simultaneous first faces 14 of alternate concrete blocks 10; (iv) simultaneous second faces 16 of alternate concrete blocks 10; and/or (v) ends 26. And sometimes, at least part of the cutting surfaces 32 of the knives 30 will not contact a particular part of an ingot 24 at all and instead hit a void space in the cutting, process for that particular cut. Preferably, the number of cuts the cutting assembly 28 will make depends on how many concrete blocks 10 are to be formed from one or more ingots 24 a-24 n, such as determined by the lengths of the ingots 24 a-24 n. Usually, there will be one more cut than the number of concrete blocks 10 to be formed from a single ingot 24. For example, in FIG. 6, each ingot 24 a-24 n forms six concrete blocks, for which there are seven cuts along each ingot 24 a-24 n. Two of the cuts, namely the first cut at time t₁ and the last cut at time t₇ form, in part, part of the ends 26 a, 26 f of the respective ingots 24 a-24 n.

Preferably, the opposing sidewalls 18 of the ingots 24 a-24 n, as well as the top faces 20 and the bottom faces 22 thereof, are formed by the molds of the ingot-making process—the inventive arrangements then defining the first faces 14 and second faces 16 thereof.

Referring again to FIGS. 1A-1C, the concrete block 10 has an approximate trapezoidal shape 12 (parallel lines shown in phantom). As previously described, a horizontal length of the first face 14 (X) is preferably longer than a horizontal length of the second face 16 (Y) as measured across the concrete block 10—i.e., X>Y. Preferably, each first face 14 of the concrete block 10 comprises at least three or more subfaces 34 as well, including one or more inner subfaces 34 b-34 d intermediate two outer subfaces 34 a, 34 e. Preferably, the one or more inner subfaces 34 b-34 d are of a total horizontal length L substantially equal to the horizontal length of the second face 16 (Y) as measured across the concrete block—i.e., L=Y. In other words, by the inventive arrangements, the total horizontal length L of the inner subfaces 34 b-34 d is approximately equal to the horizontal length of the second face 16 (Y). In addition, these subfaces 34 are preferably contoured to match one another, as will be elaborated upon. In addition, the desired subfaces 34 a-34 e of the first face 14 are formed from the contours of the cutting assembly 28 and knives 30, as are subfaces 36 b-36 d (see below) of the second face 16. These matching contours are seen in the cutting surfaces 32 of the top views of the bottom knives 30 h in FIGS. 4B and 5B (with the top knives 30 a being in mating alignment with the bottom knives 30 b).

Preferably, each of the two outer subfaces 34 a, 34 e is of a horizontal length 6, with L+G+G=X as measured across the first face 14 of the concrete block 10. In other words, by the inventive arrangements. G is approximately equal to (X−L)/(2). In addition, the two outer subfaces 34 a, 34 e are generally aligned with one another and substantially parallel to the second face 16 in relation to the trapezoidal shape 12, and the second face 16 is shorter in horizontal, length (Y) than the first face 14 (X) by approximately (2)*(G).

Preferably, each second face 16 of the concrete block 10 also comprises at least three or more subfaces 36 b-366 as well. Preferably, the subfaces 36 b-366 are of a horizontal length Y as previously described. Preferably, the subfaces 36 b-366 of the second face 16 are respectively contoured to match the inner subfaces 34 b-34 d of the first face 14 (see, e.g., FIG. 1A). Again, these matching contours can also be seen in the cutting surfaces 32 of the top views of the bottom knives 30 b in FIGS. 4B and 5B (with the top knives 30 a being in mating alignment with the bottom knives 30 b). Preferably, at least one or more of these subfaces 36 b, 36 d are generally aligned with one another and substantially parallel to the first face 14 in relation to the trapezoidal shape 12. Preferably, two or more of the inner subfaces 34 b-34 d of the first face 14 are also substantially parallel to the subfaces 36 b-36 d of the second face 16.

Preferably, transitions between the faces of the concrete block 10 are tumbled to soften the look thereof, such as between the first face 14 and the top face 20, the first face 14 and the bottom face 22, the second face 16 and the top face 20, and the second face 16 and the bottom face 22, etc.

Preferably, there is an odd number of subfaces 34 of the first face 14, such as three or five or seven or nine, etc. In another alternative embodiment, there is an even number of subfaces 34 of the first face 14, such as two or four or six or eight, etc. Preferably, the two most external subfaces 34 a, 34 e are substantially aligned with one another as shown in FIG. 1), with the inner subfaces 34 b-34 d connecting the two most external subfaces 34 a, 34 e. In another alternative embodiment, the two most external subfaces 34 a, 34 e are not substantially aligned with one another, but again with the inner subfaces 34 b-34 d connecting the two most external subfaces 34 a, 34 e (although this changes the conjugate arrangement of the concrete blocks 10 of the ingots 24 a-24 n). Likewise, there is also, preferably, an odd number of subfaces 36 of the second face 16 as well, such as three or five or seven or nine, etc. In another alternative embodiment, there is an even number of subfaces 36 of the second face 16, such as two or four or six or eight, etc. Preferably, the two most external subfaces 36 b, 36 d are substantially parallel with one another (as shown in FIG. 1), with the inner subface 36 c connecting the two most external subfaces 36 b, 36 d. In another alternative embodiment, the two most external subfaces 36 b, 36 d are not substantially parallel with one another, but again with the inner subface 36 c connecting the two most external subfaces 36 b, 36 d (although this again changes the conjugate arrangement of the concrete blocks 10 of the ingots 24 a-24 n).

In a preferred embodiment, the inner subfaces 34 b-34 db of the first face 14 match the subfaces 36 b-36 d of the second face 16 (see, e.g., FIG. 1A).

Referring now generally to FIG. 6, each of the concrete blocks 10 is substantially identical to the other concrete blocks 10, with conjugate concrete blocks 10 each facing opposing directions, both within a single ingot 24, as well as across adjacent ingots 24 a-24 n. More specifically, with each successive cut of the cutting knife 28 (e.g., cuts 17) as adjacent ingots 24 a-24 n advance together, the first faces 14 of one concrete block 10 a become the second faces 16 of the next concrete block 10 b along a particular ingot 24. In addition, a single cut from the cutting assembly 28 cuts along alternating first faces 14 and second faces 16 of alternating concrete blocks 10 in adjacent ingots 24 a-24 n, and successive cuts from the cutting assembly 28 cut along alternating first faces 14 and then second faces 16 of a same concrete block 10 a within a single ingot 24 a.

In accordance with the foregoing, one technical effect is improved dual-face dual-split concrete products, both as to the concrete blocks themselves as well as to improved cutting techniques for same.

Accordingly, it should be readily apparent that this specification describes illustrative, exemplary, representative, and non-limiting embodiments of the inventive arrangements. Accordingly, the scope of the inventive arrangements are not limited to any of these embodiments. Rather, various details and features of the embodiments were disclosed as required. Thus, many changes and modifications as readily apparent to those skilled in these arts are within the scope of the inventive arrangements without departing from the spirit hereof, and the inventive arrangements are inclusive thereof. Accordingly, to apprise the public of the scope and spirit of the inventive arrangements, the following patent claims are made: 

What is claimed is:
 1. A dual-face dual-split concrete product, comprising: a first face of horizontal length X and an opposing second face of horizontal length Y, the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X>Y; generally opposing sidewalls that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalk, with the top face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product.
 2. The concrete product of claim 1, wherein: there is an odd number of inner subfaces.
 3. The concrete product of claim 2, wherein: there are three inner subfaces.
 4. The concrete product of claim 2, wherein: were are five inner subfaces.
 5. The concrete product of claim 2, wherein: there are seven inner subfaces.
 6. The concrete product of claim 2, wherein: there are nine inner subfaces.
 7. The concrete product of claim 1, wherein: there is an even number of inner subfaces.
 8. The concrete product of claim 7, wherein: there are two inner subfaces.
 9. The concrete product of claim 7, wherein: there are four inner subfaces.
 10. The concrete product of claim 7, wherein: there are six inner subfaces.
 11. The concrete product of claim 7, wherein: there are eight inner subfaces.
 12. The concrete product of claim 1, wherein: one or more of the inner subfaces are substantially parallel to one another.
 13. The concrete product of claim 1, wherein: each of the two outer subfaces has a horizontal length of approximately (X−L)/(2).
 14. The concrete product of claim 1, wherein: the two outer subfaces are substantially parallel to the second face according to the trapezoidal shape.
 15. The concrete product of claim 1, wherein: a same cutting assembly cuts both the first face and second face of the concrete product.
 16. The concrete product of claim 1, wherein: a same cutting assembly cuts both the first face and second face of conjugate concrete products.
 17. The concrete product of claim 1, wherein: a same cutting assembly cuts both the first face and second the of conjugate concrete products across a single ingot.
 18. The concrete product of claim 1, wherein: a same cutting assembly cuts both the first face and second face of conjugate concrete products across adjacent ingots.
 19. A dual-face dual-split concrete product, comprising: a first face of horizontal length X and an opposing second face of horizontal length the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X>Y; generally opposing sidewalls that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalls, with the top face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product; and wherein the second face has one or more subfaces.
 20. The concrete product of claim 19, wherein: one or more of the subfaces of the second face are substantially parallel to one another.
 21. A dual-face; dual-split concrete product, comprising: a first face of horizontal length X and an opposing second face of horizontal length Y, the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X>Y; generally opposing sidewalls that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalls, with the top face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product; wherein the second face has one or more subfaces; and wherein one or more of the inner subfaces of the first face are substantially parallel to one or more of the subfaces of the second face. 